AME 50542: Manufacturing Processes for Engineering Materials (R.K.

Roeder)
Solidification and Crystallinity
crystalline
(e.g., metals)
semicrystalline
(e.g., polyethylene)
noncrystalline
(e.g., polystyrene
or silicate glass)
T
s
p
e
c
i
f
i
c

v
o
l
u
m
e

(
1
/

)
T
m
T
g
cooling rate
crystallinity
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Glass Transition and Melting Temperatures
MATERIAL
T
g
(C)
T
m
(C)
Nylon 6,6
Polycarbonate
Polyester
Polyethylene
High density
Low density
Polymethylmethacrylate
Polypropylene
Polystyrene
Polytetrafluoroethylene (Teflon)
Polyvinyl chloride
Rubber
57
150
73
-90
-110
105
-14
100
-90
87
-73
265
265
265
137
115
-
176
239
327
212
-
TABLE 10.2 Glass-transition and melting temperatures of some polymers.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Extruder Schematic
FIGURE 10.20 Schematic illustration of a typical extruder. Source: Encyclopedia of
Polymer Science and Technology, 2nd ed., Copyright 1985. This material is used by
permission of John Wiley & Sons.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Extruder Screw Cross Section
FIGURE 10.21 Geometry of the pumping section of an extruder screw.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Production of
Blown Film
FIGURE 10.22 Schematic illustration of
production of thin film and plastic bags from a
tube produced by an extruder, and then blown
by air. Source: D. C. Miles and J. H. Briston,
Polymer Technology, Chemical Publishing Co.,
1979. Reproduced by permission of Chemical
Publishing Co., Inc.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Injection
Molding
Schematic
FIGURE 10.23 Injection molding with (a) a plunger and (b) a reciprocating rotating screw.
Telephone receivers, plumbing fittings, tool handles, and housings are made by injection
molding.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Reaction-Injection Molding
FIGURE 10.25 Schmatic illustration of the reaction-injection molding process. Source:
Modern Plastics Encyclopedia.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Blow Molding
FIGURE 10.26 Schematic
illustrations of (a) the blow-
molding process for making
plastic beverage bottles and (b)
a three-station injection-blow-
molding machine. Source:
Encyclopedia of Polymer
Science and Engineering, 2d
ed. Wiley, Copyright 1985.
This material is used by
permission of John Wiley &
Sons, Inc.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Calendering
FIGURE 10.32 Schematic illustration of calendering. Sheets produced by this process are
subsequently used in thermoforming.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Rotational Molding
FIGURE 10.27 The rotational
molding (rotomolding or
rotocasting) process. Trash cans,
buckets, and plastic footballs can
be made by this process.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Compression
Molding
FIGURE 10.29 Types of
compression molding, a
process similar to forging: (a)
positive, (b) semipositive,
and (c) flash. The flash in
part (c) has to be trimmed
off. (d) Die design for
making a compression
molded part with undercuts.
Such designs are also used in
other molding and shaping
operations.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Transfer Molding
FIGURE 10.30 Sequence of operations in transfer molding for thermosetting plastics. This
process is particularly suitable for intricate parts with varying wall thicknesses.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Thermoforming
FIGURE 10.28 Various thermoforming processes for thermoplastic sheet. These processes
are commonly used in making advertising signs, cookie and candy trays, panels for shower
stalls, and packaging.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Casting, Potting and Encapsulation
FIGURE 10.31 Schematic illustration of (a) casting, (b) potting, and (c) encapsulation of
plastics.